Automatic looper operator and method



1963 E. J. WICK ETAL 3,100,464

AUTOMATIC LOOPER OPERATOR AND METHOD Filed Feb. 27, 1961 2 Sheets-Sheetl Aug. 13, 19-63 E. J. WlCK ETAL AUTOMATIC LOOPER OPERATOR AND METHQD 2Sheets-Sheet 2 Filed Feb. 27, 1961 VIII/llll/ll/ 4! 5:25:75!!!INVENTORS'. EDWARD J. W/CK f/A/P/P) 14 DAY United States Patent3,llii,464 AUTOMATIC LGDPER UPERATQR AND ME'IHLED Edward J. Wick andHarry W. Day, Philadelphia, Pa, assignors to Fillmore C. itoseu,Levittown, ?a., trading as Ardznore Hosiery Mills Filed Feb. 27, 1961,Ser. No. 91,759 6 Claims. (Cl. 112--27) This invention relates generallyto improvements in methods and apparatus employed in utilization oflooper machines in the hosiery industry. This application is acontinuation-in-part of our oopending patent application Serial No.58,754, new Patent No. 3,060,874, granted October 30, 1962.

While the instant method and apparatus have been primarily developed andemployed in the hosiery industry and in conjunction with loopermachines, and will be illustrated and described hereinafter withparticular reference thereto, it is understood that the invention issusceptible of many varied applications, all of which are intended to becomprehended herein.

As disclosed in our said copending patent application, operation ofconventional l'ooper machines, including the feeding thereto of hosieryfor closing the toe opening thereof has previously required skilledpersonnel, so as to be quite costly an operation. The use of unskilledpersonnel in this operation is also costly, but in the form of rejectsor defective product.

While the invention disclosed in our copending patent application issatisfactory in automatically accomplishing the desired result, theinstant invention constitutes a substantial improvement in reducing toan absolute minimum the percentage of rejects or defective product whileretaining the completely automatic operation and other advantagesdisclosed in said oopending patent application.

Specifically, the instant invention contemplates sensing the position offabric normal to the direction in which the fabric is being conveyeddirectly at the loose course which is to be positioned. Thus,positioning of the fabric layer by the instant method and apparatuseliminates the need for and use of a reference marking on the fabriclocated apart from the loose course, and further eliminates thepossibility of faulty looping resulting from distortion of fabric orother impairment of the relationship between the reference marking andloose course.

it is another object of the present invention to provide improved meansfor engagement with the fabric layers to position the same in thedirection normal to their movement tangentially of the dial.

More specifically, one aspect of the instantinvention contemplates theprovision of positioning means engaging spaced locations of a fabriclayer on opposite sides or" the loose course, which means aresynchronized to effect translation of the fabric between the engagedlocations without distortion thereof.

Other objects of the present invention will become apparent upon readingthe following specification and referring to the accompanying drawings,which form a ma terial part of this disclosure.

The invention accordingly consists in the features of construction,combinations of elements, and arrangements of parts, which will beexemplified in the construction hereinafter described, and of which thescope will be indicated by the appended claims.

-In the drawings:

FIGURE 1 is a top plan view partially illustrating a looper machine, andis showing the attachment of the present invention in association withthe looping machine, as taken along the section line 11 of FIGURE 2,with parts broken away for clarity of understanding;

FIGURE 2 is a partial sectional elevational view taken substantiallyalong the line 22 of FIGURE 1; and

FIGURE 3 is a sectional elevational view taken substantiallly along theline 33-of FIGURE 2.

Referring more particularly to the drawings, and specifically to FIGURES1 and 2 thereof, the conventional looping machine is there generallydesignated 16 and includes a generally horizontal fixed plate or table11 of generally circular-outline configuration and having a peripheralledge or upwardly facing shoulder 12 about its circumference. An annularmember or circular dial 13 extends circumferentially about the peripheryof the plate 11, being located outward therebeyond, and is provided witha radially inwardly extending flange 14 adapted to rest on the shoulder12. An annular clamping ring 15 is secured fast to the plate 11, and byfastener 16, and extends basically over the shoulder, so as to overliethe flange 14 seated on the shoulder. In this manner, the dial 13 isconventionally mounted on the plate for circular or rotary, concentricmovement relative to the plate. Suitable drive means may be associatedwith the dial 13 for effecting rotation thereof. Projecting radiallyoutward from the outer periphery of the dial 13 are a multitude ofsupport pins or points 18, which lie in a plane normal to the axis ofrotation of the dial and are adapted for successive engagement throughsuccessive loose-course stitches of an article of hose. The constructionthus far described may be conventional.

Secured to a fixed part of the looping machine, such as the fixed plate11, by any suitable means, is the attachment apparatus of the presentinvention, which is enerally designated 29. The attachment 2 may includea pair of generally coplanar mounting plates 21 and 22 of elongateconfiguration and arranged in side by-side relation having theiradjacent edges disposed generally tangential to the outer periphery ofthe dial 13. The mounting plate 21 is inward of the mounting plate 22,radially of the looper plate 11, and the inner mounting plate 21includes a coplanar inward extension 23 overlying the llooper plate 11and secured fast to the latter, as by fasteners 24.

An elongate, endless conveyor 25 is arranged longitudinally of andmounted above the mounting plate 21 for rotation about-the generallyvertical axes. In [particular, the conveyor 25 includes a pair of wheels26 and 27 disposed generally horizontally and spaced longitudinally ofthe plate 21, respectively mounted on the plate for rotation about theaxes of generally vertically disposed shafts 28 and 29 carried by themounting plate. The wheels 26 and 27 are preferably crowned in theconventional manner, and an endless belt 36 extends about the wheels.The belt 35) may be of rubber or other suitable frictional material andhas one run 31 extending generally tangential to the dial 13 along theouter edge 32 of the mounting plate.

A similar conveyor, generally designated 35, is provided on the plate22, having a pair of generally hori zontally disposed rollers 36 and 37spaced longitudinally of the mounting plate and carried thereby forrotation about the axes of vertically disposed shafts 38 and 39. Therollers 36 and 37 may also be crowned in the conventional manner, and anendless belt 40 may extend about the rollers or wheels 36 and 37 havingone run 41 extending along the inner edge 42 of the mounting plategenerally tangential to the dial 13. Thus, the runs 31 and 41 of theconveyors 25 and 35 are disposed in proximate facing relation. The belt40 of the conveyor 35 may also be of rubber or other suitable frictionalmaterial, and the belts 30 and 40 may be of the intermeshing or timedtype to positively insure equal linear velocity thereof.

The outer plate 22 is mounted on the inner plate 21 by an appropriatehinge construction 45 having a generally vertical pintle 46 extendingapproximately normal to the facing conveyor runs 31 and 41. By thishinge 45, the outer mounting plate 21 may be swung away from the innermounting plate 21 in the direction of arrow 4-7 to space the conveyorruns 31 and 41 and afford access therebetween. Any suitable resilientmeans, such as spring 48 carried by the pin 46 and connected to theelements of binge '45 may be employed to resiliently urge the plate 22toward its illustrated position with the runs 31 and 41 in facingengagement.

In operation of the looper machine 10, the dial 13 is driven in rotationby a looper drive mechanism (not shown). From rotation of the looperdial 13 is obtained power to positively drive the conveyors 25 and 35.Any suitable transmission means may be connected between the dial 13 anda vertically disposed shaft 56 journaled in and extending upward beyondthe extension portion 23 and plate 21 to rotate the shaft 56 uponrotation of the dial.

One such transmission mechanism is shown in said copending patentapplication. n the other end of shaft 56 is provided a spur gear 57which meshes with a spur gear 58 on the upper end of-shaft 29 over theconveyor roll 27. Thus, conventional rotation of the dial 13 drives theshaft 56 and its spur gear 57, which in turn drives the spur gear 58 andhence the conveyor 25. In addition, a spur gear 59 is'carried by theshaft 39 over the roll 37 of conveyor 35, which gear is in meshingengagement with the gear 53 when the mounting plate 22 is swung towardthe mounting plate 21. Thus, the gear 59 is driven from the gear 58 todrive the conveyor 35 in positive timed relation with the conveyor 25.As the dial moves in the clockwise direction, as seen in FIGURE 1, itmay be observed that the gear 57 is driven counterclockwise, and thatthe gears 58 and 59 are respectively driven clockwise andcounterclockwise to effect movement of the conveyor runs 31 and 41toward the right into substantially tangential relation with the dial13, with thefacing conveyor runs spaced over the looper pins 18 in thetangent region.

Fixed to each ofthe mounting plates 21 and 22, extending along theirrespective adjacent edges 32 and 42 are backing strips '61 and 62serving respectively to back or firm up the runs 31 and 41.

Carried by one of the mounting plates 21 and 22,

say the latter, is a locating finger generally designated 65. The finger65 may be mounted on an upstanding bar or pedestal'66 fixedly secured tothe mounting plate 22 along its inner edge 42 and upstanding therefrombeyond the runs 41 and backing member 62. The journal pedestal 66 ispreferably spaced considerably ahead of the tangent region of theconveyor runs 31 and 41. An arm 67 is pivoted at one end, as by pin 68,to the upper end of pedestal 66 and extends therefrom toward butterminates short of the tangent region of the facing conveyor runs. Atits end remote from the pivot 68, the arm '67 is provided with adepending extension or finger proper 69 entering between the facing runs31 and 41 at a location just ahead of the tangent region of the runs. Asbest seen in FIGURES 2 and 3, the extension or finger proper 69 dependsbelow the facing runs 31 and '41 to a point substantially below themounting plates 21 and 22. The finger proper or extension 69 isrelatively thin or fiat, and preferably finished to a smooth surface.Provided interiorly of the depending extension 69 at a region below theconveyor runs 31 and 34 is a miniature lamp or light source 73 energizedby any suitable means. It will now be understood that the arm 67 of thelocating finger 65 is swingable upward about the pivot 68 upon outwardswinging movement of the mounting plate 22 to separate the facing runs31 and 34, and is swingable downward to its illustrated operativeposition, preferably being releasably held in its operative position bya suitable resilient-detent means (not shown).

Carried by the mounting plate 21 are a pair of sensing elements 73:: and73b, which are preferably light-sensitive means or photocells. A pair ofsensing elements, preferably light-sensitive photocells, are alsocarried by the mounting plate 22, and designated 73a and 79b. Thelight-sensitive elements 78a and 731) are arranged on one side of thefacing runs 31 and 41, the right side as seen in FIGURE 3, with theirlight-receiving openings 8% and 8019 located in vertically spacedrelation respectively above and below the plane of points or pins 18. Inlowered, operative position of arm 67, the light source '73 carried bythe arm is located substantially in the plane of the pins 13; and, thelight-receiving apertures 80a and 8% of the photocells 78a and 7% arelocated in vertically spaced relation proximate to the light source forreceiving light therefrom, as will appear more fully hereinafter. Itwill be noted that the photocell 78b is of an angular, dependingconfiguration to avoid interference with the dial 13. This may beaccomplished by a reflecting prism, or other suitable conventionalmeans.

The light-sensitive elements or photocells 79a and 79b carried by themounting plate .22 are located with their light-receiving apertures 81aand 81b directly opposite to the apertures Stia and 8111, respectively,on the op posite side of the facing runs 41 and 31. Thus, thelight-receiving apertures 81a and 81b are spaced vertically on oppositesides of the plane of points 18 and located proximate to the lightsource 73 for receiving light therefrom. I

A pair of servo-'notors 84a and 85a are mounted in the mounting plates21 and 22, respectively, being secured by any suitable means inconforming cutouts formed in the plates. One motor 84a lies in ahorizontal plane and is carried by the mounting plate 21, while anotherhorizontal motor 85a is carried by the mounting plate 22. The motors 84aand 8511 may both lie in the same horizontal plane, respectivelyadjacent to the conveyor rollers 26 and 36, and each includes a driveshaft 86a and 87a extending obliquely toward and terminating short ofthe tangent region of facing runs 31 and 41.

Depending from each motor 84a and 85a, remote from the tangent region offacing runs 31 and 41, is a gearbox or transmission housing, as at 85bin FIGURE 2. Also seen in FIGURE 2 is a lower drive shaft 87b extendinghorizontally from the transmission housing 85b, in parallel spacedrelation directly beneath the upper drive shaft 87a. The upper and lowershafts 87a and 87b extend obliquely toward and terminate proximate tothe finger extension 69, the lower shaft 87b being located below theplane of points 18, and the upper shaft 87a being located above theplane of the points. On the extending ends of the upper and lower shafts87a and 87b1are provided frictional rollers 89a and 8%, respecti-ve y.

On the extending end of drive shaft 86a of motor 84a, there is similarlyprovided a frictional roller 88a proximate to the finger extension 69.Also, the motor 84a is provided with a depending transmission housinghaving a drive shaft and roller in the same manner as the motor 85:: thedepending transmission housing, and lower drive shaft and roller beingobscured in the drawings beneath motor 84a, shaft 86a and roller 88a.

The servo-motors 84a and 85a may be connected to the photocells on theirrespective sides of the facing runs 31 and 41. For example, theservo-motor 84a may be connected to the photocells 7 3a and 78b, whilethe servomotor 85a may be connected to the photo'cells 79a and 7%. Inthis manner, each servo-motor is operated in a respective directionresponsive to the sensing of light by the upper or lower of itsassociated'photocells. For example, should the upper photocell 78areceive more light than the lower photocell 7812,, the associated motor84a will be energized in one direction of rotation, and should the lowerphotocell 87b receive more light than the upper photocell 78a, the motor84a will be energized in the opposite direction of rotation. Theservo-motor 85a is similarly connected to the photocells 79a and 79b.Further, the lower drive shaft 87b and its roller 8% is connected by thetransmission 85b for synchronous rotation with the drive shaft 87a andits roller 89a. The lower drive shaft and roller beneath shait t 86a androller 88a is similarly connected for synchronous rotation with thelatter shaft and roller.

In this manner, each servo-motor is independently actuated responsive toenergization of its associated lightsensi-tive elements. Also, each pairof vertically spaced frictional rollers is connected for simultaneous,synchronized operation. Any suitable electrical circuitry may beemployed in connecting the light-sensitive elements to the servo-motors,such as a phase-sensitive modulator, amplifier and motor-controller;and, reduction gearing may be employed between the servo-motors andtheir output shafts, if desired.

In FIGURES 1 and 2, it may be observed that the rollers 88a, 88b, 89aand 8912 are located slightly ahead of the photocell openings @621,3011, 81a and 81b.

Proximate to the tangent region of the facing runs 31 and 41 withrespect to the dial 13, the mounting plate 22 is formed with a cutout 92opening through the inner edge 4-2. Located in the cutout 92 is aperipherally grooved push-on roller 93 which is rotatably carried on oneend of a lever 94. That is, the lever 94- is pivoted intermediate itsends on a stub shaft 95 depending rem the underside of the mountingplate 22. On one end of the lever 94 proximate to the cutout 92, theroller 93 is journaled on a generally vertical shaft or pin 96 carriedby the lever 94. The opposite end of the lever 94 is connected to aresilient member or spring 97 to resiliently bias the roller 93 towardand into rolling engagement with the peripheral edge of the dial 13. Theroller 93 is provided with a circumferential groove 5 h in alignmentwith and receiving the pins 13 of the dial 13. Thus, as best seen inFIGURE 2, the photocells 7% and 7% are located just forward of thepush-on. roller 93, and the light-receiving apertures 81a and 81b arelocated respectively above and below the horizontal plane of thepin-receiving roller groove 93.

In operation, it is only necessary to swing the mounting plate 22.outward and raise the finger arm 67. The finger extension 69 may then beengaged between the fabric layers or walls of a stocking, and properlypositioned therein by location ofthe finger-extension \arm in theforwardmost narrowing marl: of the stocking. A stocking is generallydesignated ltiti, includinv a pair of substantially identical facinglayers or walls 101 and 106,.see FIGURE 3. Each of the walls 131 and 102is conventionally formed with a row of open loops 1ll3 and 104,respectively, which open loops define the loose course, lined and placedin their aligned relation on the looper points 18.

With the locating arm 67 raised, and the facing runs 31 and 41 away fromeach other, the locating finger is engaged between the walls 101 and 1%of the stocking 160 and the finger swung downward to the position ofFIGURE 2. The forward or leading region of the stocking is properlypositioned with the open loops or loose course 103 at the same verticalheight as the support pins or points 18 for engagement of the latterthrough the open loops. The trailing region of the stocking is thenstretched to the left, the condition shownin FIGURE 2., and the mountingplate 22 swung closed for frictional engagement of the runs 31 and 41with the respective stocking walls or fabric layers 101 and 102,.

Swinging movement of the mounting plate 22 inward under the force ofspring 48 serves to engage gears 58 and 59 and cause timed rotation ofthe conveyors 25 and 35". If desired, electrical-switch means may beassociated with the movement of the mounting plate 22 to deenengize theservo-motors 84a, 84b, 85a and 35b upon opening or outward movement ofthe mounting plate 21 and energize the motors upon closing or inwardmovement of the latter mounting plate. If desired, the positioningmotors may be energized by switch means independent of movement of themounting plate 22.

In either event, with the positioning motors 84a and 85a energized andthe conveyors 25 and 35 operating to convey the stocking 100 rightwardtoward the tangential region of the runs 31 and 41, the photocells 78a,73b, 79a and 7% are operative for response to illumination received fromthe light source 73. With the loose courses or open stitches 103 and 104located as described above, and as best seen in FIGURE 3, apredetermined amount of light is passed through each of the apertures89a, 80b, 81a and 81b to the respective photocells. Should either fabriclayer, say layer 1%, be displaced vertically or in a direction normal tothe tangential direction of conveyor movement, say upward, an increasedamount of light will pass through the open loops 1&4 to the upperphotocell 79a and a reduced amount of light passed to the photocell 79b.The signal produced by the photocells in response to this upwardmovement of fabric layer 192 actuates the servo-motor 85a to rotate thepositioning rollers 89a and 89b in a direction to lower the fabric layer102 by frictional engagement therewith. Actuation of the positioningmotor 85a in the opposite direction will be effected by downwardmovement of the fabric layer 192. Similar, independent operation of theservo-motor 34a is caused in response to vertical displacement of thefabric layer 101.

Thus, monitoring of the fabric layers takes place along the loosecourse; and, corrective positioning of each fabric layer is accomplishedby engagement thereof at vertically spaced locations above and below theloose course, each pair of vertically spaced positioning rollers beingsynchronized to prevent distortion of the fabric.

The tangential relation of fabric movement by the conveyors 25 and 35with respect to the dial points 18 causes the fabric to be impaled onthe dial points. Proper positioning of the loose course, as describedhereinbefore, insures that the points 18 engage through the open loopsof the loose course. To insure full impaling of the pins or points 18through the open loops of the loose course, the push-on roller 93engages with the outer fabric layer 102, being frictionally rotated bythe latter, and resiliently urges the fabric layers radially inward ofthe dial 13 while receiving the points 18 in its peripheral groove 98.

The above-described operation proceeds until the trailing region of thestocking tilt) reaches the finger extension 6% whereupon movement of thestocking by the conveyors 25 and 35 causes the locating arm 67 andextension 69 to be swung upward for continued movement of the stockingonto the points 18. From this point, conventional looper operationoccurs, and the mounting plate may again be swung outward for insertiontherein of another stocking in the same manner as describedhereinbefore.

From the foregoing, it is seen that the present invention provides animproved method and apparatus for applying fabric layers to a loopermachine, which fully accomplish their intended objects and arewell-adapted to meet practical conditions of manufacture and use.

Although the present invention has been described in some detail by wayof illustration and example for purposes of clarity of understanding, itis understood that certain changes and modifications may be made withinthe spirit of the invention and scope of the appended claims.

What is claimed is:

1. Apparatus for applying a pair of facing layers of fabric to arotary-looper-machine dial having radial points with the points engagedin a loose course of each fabric layer, said apparatus comprisingconveyor means for conveying a pair of facing fabric layers in thedirection tangential to said dial with said loose courses on a line inalignment with said points for engagement thereon, a pair of sensingelements on the nonfacing side of each fabric layer spaced apart in thedirection normal to and on opposite sides of said line for detectingmovement of the adjacent loose course from between said sensingelements, and positioning meansiengageable with respective layers offabric and responsive to said sensing elements to move the fabric layersin said normal direction for proper positioning with respect to saidpoints.

2., Apparatus according to claim 1, said positioning means comprising arelatively smooth element adapted to be interposed between the fabriclayers, and engaging elements on opposite sides of and engageable withrespective layers of the fabric and operatively connected to saidsensing elements for engagement with and movement of the fabric layersin said normal direction.

3. Apparatus according to claim 2, said engaging means comprising a pairof rotary elements on the nonfacing side of each fabric layer spaced onopposite sides of said line for engagement with respective layer andconnected to the associated sensing elements for rotation responsivethereto and movement of the engaged fabric layer in said normaldirection.

4. Apparatus according to claim 2, said sensing elements each comprisinga photocell, and a light source interposed between said fabric layersalong said line for projecting light through said loose courses to saidphotocells.

5 In the method of applying a pair of fabric layers to a rotary-looperdial having radial points with a loose course of each layer engaged onsaid dial points, the steps which comprise: simultaneously conveying apair of facing fabric layers in the direction generally tangentialtoward said dial with the loose courses substantially aligned with saiddial points, providing a lit' t source between said fabric layers insubstantial alignment with said points, sensing light from said sourcethrough said loose courses to detect misalignment of the latter withrespect to said points, positioning said layers in the direction normalto said tangential direction to correct detected misalignment, andcontinuing tangential conveying or" said fabric layers onto said points.

6. The method according to claim 5, further characterized in positioningsaid layers by engaging each layer at spaced regions on opposite sidesof its respective loose course.

References Qited in the file of this patent UNITED STATES PATENTS2,506,053 Zuckerman May 2, 1950 2,599,666 Snrridge June 10, 19.522,827,809 Beam Mar. 25, 1958

1. APPARATUS FOR APPLYING A PAIR OF FACING LAYERS OF FABRIC TO AROTARY-LOOPER-MACHINE DIAL HAVING RADIAL POINTS WITH THE POINTS ENGAGEDIN A LOOSE COURSE OF EACH FABRIC LAYER, SAID APPARATUS COMPRISINGCONVEYOR MEANS FOR CONVEYING A PAIR OF FACING FABRIC LAYERS IN THEDIRECTION TANGENTIAL TO SAID DIAL WITH SAID LOOSE COURSES ON A LINE INALIGNMENT WITH SAID POINTS FOR ENGAGEMENT THEREON, A PAIR OF SENSINGELEMENTS ON THE NONFACING SIDE OF EACH FABRIC LAYER SPACED APART IN THEDIRECTION NORMAL TO AND ON OPPOSITE SIDES OF SAID LINE FOR DETECTINGMOVEMENT OF THE ADJACENT LOOSE COURSE FROM BETWEEN SAID SENSINGELEMENTS, AND POSITIONING MEANS ENGAGEABLE WITH RESPECTIVE LAYERS OFFABRIC AND RESPONSIVE TO SAID SENSING ELEMENTS TO MOVE THE FABRIC LAYERSIN SAID NORMAL DIRECTION FOR PROPER POSITIONING WITH RESPECT TO SAIDPOINTS.